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IS 14177 (1994): Guidelines for painting system for

hydraulic gates and hoists [WRD 12: Hydraulic Gates and
Valves]

“!ान $ एक न' भारत का +नम-ण”

Satyanarayan Gangaram Pitroda
“Invent a New India Using Knowledge”

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है”
ह
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“Knowledge is such a treasure which cannot be stolen”
 IS14177:1994
( Reaffirmed 2004 )

Indian Standard
GUIDELINES FOR PAINTING SYSTEM FOR
HYDRAULIC GATES AND HOISTS

UDC 626.422'2
:621'75)5'3

BUREAU OF INDIAN STANDARDS

MANAK BHAVAN. 9 BAHADUR SHAH ZAFAR MARG
NEW DELHI 11ooU2

Octohr 1994 Price Group 3

Hydraulic Gates and Valves Sectional Committee, RVD 12

FOREWORD

This Indian Standard was adopted by the Bureau of Indian Standards, after the draft finalized by the
Hydraulic Gates and Valves Sectional Committee had been approved by the River Valley Division
Council.

Gates, its embedded parts, hoists and-its supporting structures should be protect4 against corrosion due
to climatic condition, biochemical reaction and abrasion due to different forces acting on it, otherwise
these equipments may deteriorate to an extent that the replacement of parts may bccomc necessary and
such replacementswill become very difficult. It is, therefore, recommended that a suitable painting system
should be adopted.

In the formulation of this standard assistance from the following publications have been &rived:
1) ISO-8501-l : 1988 Preparation of steel substrates bcforc application of paints and related
products - Visual assessment of surface clcanlincss.
2) BS 4232 : 1967 Specification for surface finish of blast-clcancd slccl for painting.
3) Swedish Standard SlSU55900 Rust grades for steel surfaces and preparation grades prior to
protective coating.

For the purpose of deciding whether a particular requircmcnt of this standard is complied with, the final
value, observed or calculated expressing the result ofa test or analysis, shall be rounded off in accordance
with IS 2 : 1960 ‘Rules for roundin!: off numerical values (rer*ised)‘. The numhcr of significant places
retained in the rounded off value should be the same as that of the specified value in this standard.

Indian Standard
GUIDELINES FOR PAINTING SYSTEM FOR
HYDRAULIC GATES AND HOISTS
1 SCOPE
This standard lays down the methods of prepara-
tion of steel surfaces, painting operation and paint
system applicable to hydraulic gates, hoists and
their supporting structures.
2 REFRRENCES
The Indian Standards listed below are necessary
adjuncts to this standard.
IS No. Title
1477 (Part 1) : Code of -practice for painting of
1971 ferrous metals in buildings: Part I
Pretreatment (first rrvision)
1477 (Part 2) : Code of practice for painting of
1971 ferrous metals in buildings: Part 2
Painting (first revision)
2339 : 1963 Aluminium paint for general
purposes in dual container.
2932 : 1974 Enamel, synthetic, exterior (a)
undercoating (b) finishing (ftrst
revbion)
3 SELECTION OF PAINTING SYSTEM
3.0 The following factors should determine the
type of painting system to be adopted:
a) Location;
b) Climatic condition;
c) Water quality, for example, Salinity, and
d) Composition of paint. ’
3.1 Lomtion
The painting system to be adopted depends on
location of the structure, component or equipment
relating to water exposure that is whether it is
submerged under water, partially submerged
under water, above water, occasionally submerged
under water or is to be in contact, with concrete
surface.
3.2 C@natic Conditions .i
The climatic condition of the area where the equip-
ment is to be installed also plays a part in the
selection of painting system.
3.3 The pH value and salinity -of water is to be
considered while selecting the type of finish coat.
IS 14177 : 1994
3.4 The chemical composition of the paint should
be considered while selecting the type of paint.
4 SURFACE PREPARATION PRIOR TO
APPLICATION OF PAINT
4.0 For adherence and durability of the paint
system it is extremely important that a suitable
surface preparation is carried out.
4.1 The factors which influence the performance
of painting system are:
a) Presence of mill scale and rust.
b) Presence of foreign material such as oil,
grease, etc.
c) Profile of the surface.
d) Presence of welded surface, spatter and
sharp projects.
4.2 Types of Surface Preparation
4.2.1 Blast Cleaning
Surfaces requiring blast cleaning should be sand/
grit/shot blasted after fabrication prior to painting.
Heavy deposits of grease or oil may be removed by
the solvent like clean mineral, spirits, xylol or
white, gasoline, etc. prior to sand blasting. Small
quantities of grease or~oil may be removed by the
blasting process in which case, however, the
abrasive should not be reused if it contains sufft-
cient oil or grease to render it unsuitabie for blast
cleaning purposes. The average surface roughness
after sand-blasting should not exceed 40 microns.
Blast cleaning should be performed with sand/
grit/shot as per requirements given.in IS 1477 (Part
1) : 1971.After-blast cleaning, thesurfaceshouldbe
cieatied from loose dust.and debris preferably by air
blast with the help of blower.
For the purpose of surface preparation, blast clean-
ing is classified into four classes as given in 4.2.1.1
to 4.2.1.4.
4.2.1.1 Class ‘A’
This is the best quality of Blast cleaning. Whole
surface of steel should be cleaned to bare metal
without any res’idual~inany form.
4.2.1.2 Class ‘B’ , : ,. _,
Under this class at least 95 percent of surface of
steel should be cleaned to bare metal except some
tightly bonded residue in the form of millscale/rust
1
IS 14177 : 1994

only. The extent of residue should not be more than be allowed to dry or to harden before the succeed-
10 percent of any single square having an area of ing coat is applied. Newly cleaned or painted sur-
6.25 cm’. face should remain in a covered shop protected
4.2.1.3 Class ‘C’ from moisture, condensation, contamination and
freezing temperatures until the paint is thoroughly
Under this. class at least 80 percent of surface of cured. Each coat should be thoroughly dried and
steel should be cleaned to bare metal except some cured before application of succeeding coats. Care
tightly bonded residue in the form of millscale/rust shauld be taken to prevent contamination of sur-
only. The extent of residue should not be more than faces between coats of paint.
40 percent of any single square having an area of
6.25 cm2. All coats should be applied in such a manner that
produce an even film of uniform thickness com-
4.2.6.4 Class ‘II’ pletely covering all corners and crevices. Coating
Under this class at least 65 percent of surface of should be done by qualified workers experienced in
steel should be cleaned to bare metal except some applying the specific coating materials.
tightly bonded residue in the form of millscale/rust
only. The extentof residue should not be more than Thinner should not be added to any paint. How-
60 percent of any single square having an area of ever, if used, solvents should be compatible with the
6.25 cm2. paint materials being applied.
4.2.2 Hand and Power Toal Cleaning Spray application should be performed with airless
spray equipment. Spray guns should be suited to the
Surfaces should be prepared. by hand and power type of paint being used and,‘should be operated
tool cleaning such as scraping, wire. brushing, with orifices, nozzles and air pressure suited to the
machine brushing and grinding. Prior to hand and type of paint and its consistency. Paint .pofs should
power tool cleaning, any heavy layer of rust should
be equipped with means of controlling air or liquid
be removed by chipping, visible oil, grease, dirt and pressure~on the pot independently of the-pressure
other foreign material should be cleaned,by using
of the gun. Airlines should be equipped with water
solvents by the use of clean mineral spirits, xylol or
traps for positive removal of condensed moisture.
white gasoline. After hand and power tool cleaning,
the surface should be cleaned of loose dust and Brush application of priming coats should be
debris. Before application of primer coat an absor- avoided. If brush is to be applied, paint material
bant is preferably applied to remove very fine dust. shouldbe applied with succeeding coats, each coat
This type of surface preparation may be used only of uniform coverage, well brushed out, leaving no
in the case of small components of the hoist equip- defects.
ment where blast cleaning is not feasible. All cleaning, surface preparation and coating ap-
5 PAINTING plication work should be done after the parts are
completely fabricated and machine finished and
5.1 Application of Paints
checked in the shop. The parts should be dis-.
Surface preparation leaves the material in vul- assembled to the extent necessary to enable clean-
nerable condition. It is therefore essential that im: ing and coating, those surfaces, which are inacces-
mediately after surface preparation but not later sible while assembled. After finish coating and
than a time gap of 6 hours, the pFepared surface of c’urirtg,part should be reassembled as required for
the steel metal should be covered with a primer shipment and coating on bolts or connections that
coat. will not be removed in erection should be touched
up. if some surfaces are in accessible for painting
A primer coat cannot be expected to last for an
the coating should be applied by sheep skin
extensive period. It must receive finish coats before
daubers.
it deteriorates. Primer coated articles in storage
should be examined every few weeks to determine Roller application of coating system should be
whether additional painting is needed. avoided.,If it is essential to use the coating material
The air temperature at the time of application must so applied it should be uniform and in even coats,
not be below 1OOCandrelative humidity should not without defects. The second coat should be applied
be above 90 percent. Paint material should be at-right angle to the first coat.
thoroughly mixed at the time of application. Each 5.2 Painting System
coat of primer and paint should becompatible with
_the previous and subsequent coats. Each coat The painting system should preferably be carried
should be free from runs, drops, pinholes, wave, out in the shop in order to ensure good quality
laps, sags and unnecessary brush marks and should control. Considering the facility available in the

2

shop,that is, the sand/shot blasting, the application
of primer coat should invariably be carried out in
the shop.
The first finishing coat should also preferably be
carried out in the shop. If due to practical reasons
the finishing coat is applied in the field the finished
coat should be applied within the ‘time gap per-
mitted by the paint manufacturer between the
primer coat and finished coat. In some cases final
coat of finished paint may be carried out in the field
if inter coat bond permits.
During .painting operations, all stainless steel,
bronze nickel and other machined surface adjacent
tometal work to be painted should be protected by
covering with masking tape or other suitable
means.
Metal work which has been shop painted should be
handled with care so as to preserve the shop coat in
the best practicable conditions. Before proceeding
with any painting operation, the base metal should.
becleaned and all the areas of the shop paint which
are defective’ or damaged should be repainted.
Metal work adjacent to field weld, rivetting or bolt-
ing where the shop paint coating has been damaged
due to handling or due to heat.should be cleaned
thoroughly to expose the base metal and should be
repainted. Paint applied to such areas should be of
the same types as used for the original shop coat.
During assembly/fabrication the surface on which
another member overlaps for welding should be
cleaned and painted and then the secondary mem-
ber should be placed on the primary member to
avoid surface left unpainted. Heat resistant paint
should be used.
5.2.1 Gates and Appurtenances
5.2.1.1 Surface preparation
The following classes of blast cleaning for surface
preparation should be adopted. Details of classes
are given in 4.2.1.
1) Gates and stop logs - As per Class B or
Class A
2) Liftingbeams - As peKlass C or Class B.
3) Exposed embedded parts - As per Class B
or Class A.
5.2.1.2 JXmer coat
After surface preparation the following primer
coats should be applied:
1) Gates and stoplogs - Over the prepared
surfaces one,coat of Inorganic zinc silicate
(Preferably airless spray) should be applied
giving a dry film thickness of 70 + 5 microns.
Alternatively two coats of zinc rich primer
3
IS 14177 : 11994
(containing not less than 85% zinc on dry
film) should be applied to give a total dry
film thickness of 70 f 5 microns.
2) Lifting beamlhfting tackles - Over the
prepared surfaces two coats of zinc phos-
phate primer should be applied giving a dry
filin thickness of 40 microns per coat.
3) Exposed embedded parts - Over the
prepared surfaces one coat of inorganic zinc
silicate primer (preferably air-less spray)
giving a dry film thickness of 70 + 5 microns
should be applied. Alternatively two coats
of zinc rich primer (containing not less than
85% zinc on dry film) should be applied to
give a total dry film thickness of 75 +- 5
microns.
5.2.1.3 Finishing coats
Over the primer coats the following finished coats
should be applied:
1) Gates and stoplogs - Finishing coat should
consist of two coats of solventless coaltar
epoxy paint. These should be applied at an
interval of 24 hours. Each coat should give
a minimum dry film thickness of 150 + 5
microns. The total dry film thickness of all
the coats including primer coating should
not be less than350 microns.
2) Lifting beam - Finishing coat should con-
sist of two coats of alkyd based micaceous
iron oxide paint. Each coat of paint should
give a minimum dry film thickness of 65 + 5
microns. The interval between coats should
be 24 hours. The total dry film thickness of
all coats including primer coating should
not be less than 200 microns.
3) Exposed embedded parts - Finishing coat
consist of two coats of solventless coaltar
epoxy paint. These should be applied at an
interval ofabout 24 hours. Each coat should
give a dry film thickness of 150 rf: 5 microns.
The total dry film thickness of~all the coats
including primer coating should not be less
than 350 microns.
5.2,2 Hoists and Supporting Structure
5.2.2.1 Srrflace preparation - Should be done as
per the requirements of Class B given in 4.2.1.2.
In case thesurface preparation is done manually by
wire brush, mechanical tools, etc, instead of sand
blasting all ferrous surfaces exposed to atmosphere
or water shall be given a coat of rust inhibitive
phosphate wash by brush immediately following
cleaning operation and surface shall be thoroughly
wetted with rust inhibitive wash at a rate ap-
IS 14177 : 1994

proximately 30 ml/m2 and allowed to dry for 24 ing to IS 2339 : 1963 Dr Synthetic enamel
hours. Rinsing after applications is generally not conforming to IS 2932 : 1974 to give a dry
required but unreached residue if any shall be film thickness of 25 + 5 micrpns/cbat.
removed by wiping the inhibited surface with damp 3) Hydraulichoist - AlLunmachined ferrous
cloth, within one hour after rust inhibiting wash has surfaces (hoist cylinder, cylinder heads,
dried thoroughly and after removing unreacted hydraulic piping, pCpe fittings, bonnet
residue, the application of primer and painting as cover) exposed to water should be given two
indicated in the following paragraph shall be car- coats of solventless coal tar epoxy paint.
ried out. Each coat should give a dry film thickness of
5.2.2.2 Primer coat 150 f 5 microns. Total dry film thickness of
all the coats including primer coat should
1) Structural component - Two coats of zinc not be less than 350 microns. Surfaces unex-
phosphate primer should be applied. Dry posed to water should be given one coat of
film thickness of 40 + 5 micron per coat alkyd based micaceous iron,oxide paint to
should be given. give dry film thickness of 65 k 5 microns
2) Machinery - Except machined surfaces, all followed by two coats of synthetic enamel
surfaces of the~machinery including gearing paint conforming to IS 2932 : 1974 to give
housing, shafting bearing pedestals, etc, dry film thickness of 25 + 5 microns/coat.
should be given one coat of zinc phosphate The interval between coats should be 24
priming paint to give a minimum dry film hours. The total dry film thickness should
thickness of 50 microns. Motors and other not be less than 175.microns. Oil tank, con-
bought out items should also be painted if trol cabinet, hoist beams, pipe supports and
necessary. clamps, ladders, etc, should be given three
3) Hydraulic hoist - All unmachined ferrous coats of aluminium paint conforming to
surfaces (hoist cylinder, cylinder heads, IS 2339 : I%3 or synthetic enamel conform-
hydraulic piping, pipe fittings, bonnet ing to IS 2932 : 1974 to give a dry film
covers) exposed to water should .be given thickness of 25 2 5 microns per coat. The
one coat of inorganic zinc silicate (prefer- total dry film thickness of all the coats in-
ably airless spray) to give a dry film thickness cluding primer coat should not be less than
of 70 & 5 microns and surfaces unexposed 125 microns.
to water should be given two coats of zinc 41 Unmachinedsurfnces-The unfinished sur-
phosphate primer paint giving a dry film faces of the piston and the unfinished
thickness of 40 f 5 microns/coat. Oil tank surfaces of cylinder heads should be cleaned
control cabinets, hoist beams and pipe sup- and given three coats of vinyl resin/
port should be given one coat of zinc phos- chlorinated rubber to give a dtyfilm thick-
phate priming paint giving a minimum dry ness of 30 + 5 microns/coat, to obtain a
film thickness of 50 + 5 microns. minimum dry film thickness of 125 microns
Unmachined surfaces - All unmachined including primer coat.
4)
surfaces should be given one primer coat of 5.2.3 Machined Surfaces
chlorinated rubber based zinc phosphate
primer togive a dry film thickness of 50 + 5 All machined surfaces of ferrous metal including
microns. screw threads which will be exposed during ship
ment or while awaiting installation should be
5.2.2.3 Finishing coats
cleaned by suitable solvent and given a heavy
1) Structural component - The finish paint uniform coating of gasoline soluble removable rust
should consist of one coat of alkyed based preventivecompound orequivalent. Machinedsur-
micaceous iron oxide paint at dry l”tlm faces should be protected with the adhesive tapes
thickness of 65 f 5 followed by two or other suitable means during the cleaning and
coats of synthetic enamel paint conform- painting operation of other components.
ing to IS 2932 : 1974 to give dry film thick-
S.2.4 Painting of Embedded Parts in Contact with
ness of 25 + 5 microns per coat or synthetic
enamel paint. The interval between.coats Concrete
should be 24 hours. The total dry film thick- All surfaces of embedded parts which are to come
ness of all the coats including primer coat in contact with concrete should be cleaned as given
should not be less than 175~microns. in 4.2.1.4 to meet the requirements of class D and
-21 Machinery-The finish Paint should consist should be given a coating of cement latex to prevent
of three coats of aluminium paint conform- rusting. Exposed machined surfaces of ferrous

4

metal which are to be in rolling and sliding contact
should not be painted but should bc coated with
heavy gasoline soluble rust preventive compound.
In all exposures where metal will be partially cm-
bedded in concrete, it is good practice to extend the
protective coating on the nonembedded portion a
short distance into the area later to be emhcdded,
thus eliminating problem at the junction point.
52.5 Su$ices not to be Pointed
The following surfaces are not to be painted unless
or otherwise specified:
a) Machine finished or similar surfaces: How-
ever, such surfaces should be protected with
a corrosion preventing compound.
b) Surfaces which will be in contact with concrete.
cl Stainless steel overlay surfaces.
4 Surfaces in sliding or rolling contact.
e) Galvanized surfaces, brass and bronze
surfaces.
9 Aluminium alloy surfaces.
8) Bare electrical conductors and insulating
materials.
h) Equipment name plates and instructions.
5.2.6 Handling Painted Metnl .Work
Metal work to be transported by rail or truck should
be loaded so as to prevent shifting and scuffing or
gauging of the coating. In loading and unloading
and during installation reasonable cart and
suitable handling equipment should be employed
to keep abrasion damage at a minimum.
IS 14177 : 1994
6 INSPECTION ANI) ‘I’EWING
6.0 Inspection and testing of paint should be car-
ried out- in accordance with the provisions laid
down in IS 1477 (Part 2) : 1071.
7 MAINTENANCE OI’I~HA’I’ION
7.0 As a part of maintenance operation, all gates,
embedded pyrts and hoists should be inspected at
least at an interval of 2 years. If repainting is con-
sidered necessary, surface preparation should be
carried out by appropriare hand and power tool
cleaning. Visible oil, grcasc, dirt and other foreign
material should bc cleaned by using solvents by the
use of clean mineral spirits, xylol or white gasoline.
While attending lo the maintenance painting. It is
not ordinarily intended that total sound adherent
old paint hc removed unless it is excessively thick
or flexible. Howcvcr,specific instructionsshould be
given on the exlcnt Of surface to be blast cleaned
while repainting.
In preparing a previously painted surface, it is
necessary to remove all corrosion and all ~paint
which shows evidence of corrosion, peeling, exces-
sivc thickness. brittleness, blistering, scaling or
general disinlcgration. It is essential that the
removal of rhe old paint be carried back around the
edges of rhc sporr of area until an area of complete-
ly intacr and adhering paint film, with no rust, or
biislcrs underneath is atlained. Edges of tightly
adhcrcnt paint remaining around the area to be
rccoalcd musl hc fcathcrcd, so that the repainted
surface can have a smooth appcarancc. The remain-
ingold paint should havcsufficicnt adhesionso that
it cannol bc Wed as a layer by inserting a blade of
a dull putty knife under it.
Bureau of Indian Standards

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promote harmonious development of the activities of standardization, marking and quality
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grade designations. Enquiries relating to copyright be addressed to the Director ( Publications), BIS.

Review of Indian Standards

Amendments are issued to standards as the need arises on the basis of comments. Standards are
also reviewed periodically; a standard along with amendments is reaffirmed when such a review
indicates that no changes are needed; if the review indicates that changes are needed, it is taken
up for revision. Users of Indian Standards should ascertain that they are in possession of the
latest amendments or edition by referring to the latest issue’of ‘BIS Handbook’ and ‘Standards
Monthly Addition’.

This Indian Standard has been developed from Dot : No. RVD 12 ( 32 ).

Amendments Issued Since Pablication

Amend No. Date of Issue Text Affected

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